Process for making a hybrid ceramic article

Abstract

A process for making a hybrid ceramic article is disclosed. The process involves embedding an array of refractory ceramic tiles in a fiber reinforced glass-ceramic matrix composite substrate. The hybrid ceramic article so formed exhibits high thermal stability and elevated temperature load-bearing ability.

We claim: 
     
       1. A process for making a hybrid ceramic article, comprising: providing a plurality of refractory ceramic tiles, said tiles each having a protective region for covering a substrate and a supportive region extending from the protective region for securing the tile to the substrate,   embedding the supportive region of each of the refractory ceramic tiles in a layer of fibers,   impregnating the layer of fibers with a glass or glass ceramic matrix material to form an impregnated fiber layer,   consolidating the impregnated fiber layer to form the substrate, said hybrid ceramic article having an array of refractory ceramic tiles embedded in a fiber reinforced glass ceramic matrix substrate and said hybrid ceramic article exhibiting high thermal stability and elevated temperature load-bearing ability.   
     
     
       2. The process of claim 1, wherein the layer of fibers, a stack of woven fiber cloth and the supportive regions of the refractory ceramic tiles are embedded by forcing the supportive region of the refractory ceramic tiles between the fibers of the woven fiber cloth. 
     
     
       3. The process of claim 1 wherein the layer of fibers is impregnated with matrix material by applying a slurry of glass or glass-ceramic powder to the fibers prior to embedding the supportive regions of the tiles. 
     
     
       4. The process of claim 1 wherein the layer of fibers is impregnated by transfer of the glass or glass ceramic matrix material into the fiber layer after embedding the supportive regions of the tiles. 
     
     
       5. The process of claim 1, additionally comprising: bonding an array of selectively positioned refractory ceramic tiles to a sheet of metal foil with an adhesive prior to embedding the supportive region of each of the tiles in a layer of fiber, and heating the thermal barrier in air after consolidating the glass impregnated fiber layer to decompose the adhesive and disbond the array of selectively positioned refractory ceramic tiles from the sheet of metal foil.   
     
     
       6. A hybrid ceramic article, made by the process of claim 1.